Panel construction system

ABSTRACT

A panel construction system includes a plurality of rails and a plurality of panels. Each rail has a longitudinally-extending base with opposing longitudinally-extending L-shaped sides coupled to at least a portion of the base to thereby define a longitudinally-extending T-shaped channel. Each panel defines a longitudinally-extending T-shaped channel that is recessed within an outer surface of the panel at one end thereof and extends from the outer surface at an opposing end of the panel. One or more of the panels can incorporate at least one auxiliary-function feature such as solar energy conversion features.

Pursuant to 35 U.S.C. §119, the benefit of priority from provisional application 61/466,934, with a filing date of Mar. 24, 2011, is claimed for this non-provisional application.

FIELD OF THE INVENTION

The invention relates generally to construction systems, and more particularly to a construction system utilizing an arrangement of rails with panels installed thereon.

BACKGROUND OF THE INVENTION

A structure's walls and roof typically have wood or metal studs with exterior sheathing attached to the studs and exterior finishing material attached to the sheathing and studs. Wall framing/sheathing must be altered to accommodate windows, doors, etc. This requires extra labor and special skills. The framing/sheathing/finishing associated with roofs typically requires workers (i.e., “roofers”) to operate on a variety of slanted/angled surfaces. This type of operating environment is frequently the source of worker accidents. When asphalt shingles are used to finish a roof, the shingles must be replaced every 15-20 years. In both roof repair and replacement scenarios, roofers must navigate and operate from the roof's outer surface thereby placing them at risk for injury.

In recent years, a structure's ability to be “green” (i.e., energy efficient, using solar energy, using geothermal energy, etc.) has become the focus of many architects and builders. One of the most well known “green” technologies is the solar panel that incorporates photovoltaics (for electricity generation) or tubes carrying flowing fluid/water (for heat and/or hot water generation). Such solar panels are typically installed on top of a roof's framing/sheathing/finishing structure. Accordingly, solar panel installation and repair also requires workers to operate on the various slants/angles inherent in most roof designs. This increases the cost and risk of going “green.”

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide an improved construction system.

Another object of the present invention is to provide a construction system that simplifies the construction of walls and roofs.

Still another object of the present invention is to provide a construction system that greatly reduces the risks associated with roof installation/repair and solar panel installation/repair.

Yet another object of the present invention is to provide a construction system that can readily integrate new technologies into a structure's walls and roof.

Other objects and advantages of the present invention will become more obvious hereinafter in the specification and drawings.

In accordance with the present invention, a panel construction system includes a plurality of rails and a plurality of panels. Each rail has a longitudinally-extending base with opposing longitudinally-extending L-shaped sides coupled to at least a portion of the base to thereby define a longitudinally-extending T-shaped channel. Each panel defines a longitudinally-extending T-shaped channel that is recessed within an outer surface of the panel at one end thereof and extends from the outer surface at an opposing end of the panel. Each side of the panel's channel slidingly engages one of the sides of one of the rails. One or more of the panels can incorporate at least one auxiliary-function feature such as solar energy conversion features, light transmission features, air transmission features, energy transmission features, and condition sensing features.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and advantages of the present invention will become apparent upon reference to the following description of the preferred embodiments and to the drawings, wherein corresponding reference characters indicate corresponding parts throughout the several views of the drawings and wherein:

FIG. 1 is a perspective view of a mounting rail for use in a panel construction system in accordance with an embodiment of the present invention;

FIG. 2A is an end view of a mounting rail incorporating a framing-member mounting flange in accordance with an embodiment of the present invention;

FIG. 2B is a an end view of a mounting rail incorporating a framing-member mounting trough in accordance with another embodiment of the present invention;

FIG. 2C is an end view of a mounting rail incorporating a framing member in accordance with yet another embodiment of the present invention;

FIG. 2D is an end view of a mounting rail incorporating a framing member in accordance with still another embodiment of the present invention;

FIG. 3A is a perspective view of a panel at one end thereof where the panel is to be used in a panel construction system in accordance with an embodiment of the present invention;

FIG. 3B is a perspective view of the panel in FIG. 3A from the opposing end thereof;

FIG. 4 is a partially exploded perspective view of an installation configuration of a panel construction system in accordance with an embodiment of the present invention;

FIG. 5A is a schematic plan view of a panel incorporating solar energy conversion features in accordance with an embodiment of the present invention;

FIG. 5B is a schematic plan view of a panel incorporating light transmission features in accordance with an embodiment of the present invention;

FIG. 5C is a schematic plan view of a panel incorporating air transmission features in accordance with another embodiment of the present invention;

FIG. 5D is a schematic plan view of a panel incorporating energy transmission features in accordance with another embodiment of the present invention;

FIG. 5E is a schematic plan view of a panel incorporating condition sensing features in accordance with another embodiment of the present invention;

FIG. 6 is a perspective view of a panel incorporating handles in accordance with another embodiment of the present invention;

FIG. 7A is a perspective view of a panel at one end thereof where the panel is to be used in a panel construction system in accordance with another embodiment of the present invention; and

FIG. 7B is a perspective view of the panel in FIG. 7A from the opposing end thereof.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a panel construction system that can be used to construct portions or entireties of a variety of structures such as buildings, free-standing walls, fences, etc. In term of buildings, the panel construction system can be used to construct exterior/interior walls and roofs. As will be explained further herein, the panel construction system can comprise purely structural elements or can include elements that provide a variety of auxiliary functions. Accordingly, it is to be understood that the exemplary embodiments described herein illustrate just a few of the options that are possible using the novel features of the present invention.

Referring now to the drawings and more particularly to FIG. 1, an embodiment of a single mounting rail used in the present invention's panel construction system is shown and is referenced generally by numeral 10. A number of such mounting rails will be used in the present invention's panel construction system as will be explained further below. Rail 10 is generally made from a rigid material such as metal, plastic, fiberglass, composites, etc., the particular choice of which is not a limitation of the present invention. Rail 10 is a generally elongate element having a base 12 (e.g., a planar base) with opposing sides 14 and 16 coupled to and extending along the length of base 12. More specifically, side 14 is a longitudinally-extending and continuous L-shape all along the length of base 12. Side 16 is a longitudinally-extending and discontinuous or notched L-shape all along the length of base 12. That is, side 16 can be viewed as two L-shaped regions 16A and 16B separated from one another along base 12 by a gap 16C of distance D. The purpose of separated L-shaped regions 16A and 16B will be explained later herein. The above-described structure results in rail 10 defining a T-shaped channel 18 along most of the length thereof. In other words, with the exception of gap 16C, sides 14 and 16 are mirror images of one another.

Each such mounting rail 10 can be attached via its base 12 to an existing framing member (e.g., wall stud, roof rafter, etc.). The mounting rails of the present invention can also include features to facilitate their incorporation into a structure. For example, mounting rail 10A (illustrated in an end view in FIG. 2A) includes a single mounting flange 20 extending from base 12 that can be used to attach rail 10A to and along a framing member 100 (illustrated using dashed lines to indicate that framing member 100 is not part of the present invention). Attachment can be made using conventional fasteners (not shown) such as nails, screws, staples, and/or adhesive. FIG. 2B illustrates another mounting rail 10B that includes a mounting trough 22 for capturing framing member 100 therebetween and for attachment thereto. Another option is illustrated in FIG. 2C where a mounting rail 10C incorporates a framing member 24 as part thereof thereby eliminating the need for conventional framing. Yet another option is illustrated in FIG. 2D where mounting rail 10D has its base 12 extending beyond sides 14 and 16 to form flange regions 12A and 12B so that rail 10D is readily positioned across (i.e., perpendicular) and attached to framing members (e.g., horizontally attached to vertical wall studs with a portion of one framing member/stud being indicated by reference number 100). Note that the inclusion of a mounting flange(s), trough or framing member with the mounting rail also improves the overall strength and rigidity of the mounting rail.

Referring now to the opposing end views presented in FIGS. 3A and 3B, an embodiment of a single panel used in the present invention's panel construction is referenced generally by numeral 30. A number of such panels will be used in the present invention's panel construction system as will be explained further below. FIGS. 3A and 3B only depict the important structural aspects of panel 30 as other features that could be included in the panel will be presented later below. Panel 30 is generally of rigid construction and can be made from a wide variety of materials (or combinations thereof) without departing from the scope of the present invention. Panel 30 includes an outer region/surface 32 and an inner region/surface 34. Regions 32 and 34 can be an integrated structure or could be an assembled structure without departing from the scope of the present invention. For purpose of the present invention, inner region 34 defines an open-ended T-shaped channel 36 that extends the length of inner region 34. Further, inner region 34 is recessed within outer region 32 at one end of panel 30 (FIG. 3A), and inner region 34 extends from outer region 32 at an opposing end of panel 30 (FIG. 3B). The length L of inner region 34 is less than the length (i.e., distance D) of gap 16C shown in FIG. 1. At the recessed portion of inner region 34 illustrated FIG. 3A, one or more indexing pins 38 can be provided and extend longitudinally from inner region 34 but not beyond the confines of outer region 32. When pins 38 are included, corresponding indexing recesses 40 can be provided and extend into the protruding portion of inner region 34 as illustrated in FIG. 3B. Each pin 38 is longitudinally aligned with a corresponding recess 40 along the length of panel 30.

An exemplary construction configuration of a panel construction system in accordance with an embodiment of the present invention will now be described with the aid of FIG. 4 where common reference numerals will be used to refer to elements described previously herein. For clarity of illustration, each mounting rail 10 is illustrated without the second L-shaped region (i.e., region 16B in FIG. 1). Further, it is to be understood that mounting rail 10 could exclude this second L-shaped region without departing from the scope of the present invention.

In the exemplary construction configuration, a plurality of rails 10 (e.g., two are illustrated) are arranged parallel to one another. Rails 10 could be part of a wall or roof structure, and could be arranged vertically or horizontally without departing from the scope of the present invention. A plurality of panels 30 are mounted on rails 10. One such panel 30 is illustrated just prior to its installation on the two adjacent rails 10. Installation will be described with reference to the “about-to-be-installed” panel 30. Referring to the illustrated orientation, the left edge of panel 30 is placed in the left rail 10 such that one side of T-shaped channel 38 engages L-shaped side 14. Next, the right side of panel 30 can readily drop into the right rail 10 via its gap 16C that is at least as long as the length L of inner region 34 of panel 30. Panel 30 is then slid along mounting rails 10 until it nests with an adjacent panel 30 installed on the same pair of mounting rails. That is, the recessed portion at one end of a panel 30 (shown in FIG. 3A) nests within a protruding portion of an opposing end of an adjacent panel 30 (shown in FIG. 3B). If the above-described pins 38 and recesses 40 are provided on panels 30, the nesting of adjacent panels 30 will provide for the engagement of one panel's pins with an adjacent panel's recesses. The resulting overlapping of adjacent panels installed on shared mounting rails provides structural rigidity as well as a moisture barrier. Sealing material (e.g., gaskets, caulk, etc.) could also be provided where two panels nest for enhanced moisture protection.

Once a pair of adjacent mounting rails 10 is fitted with panels 30, a retaining clip 50 can be used to fill gap 16C. For example, clip 50 can define a C-shaped channel that engages mounting rail 10 at gap 16C so that the combination of rail 10 and clip 50 at gap 16C define an L-shaped side similar to side region 16A. In FIG. 4, one clip 50 is shown prior to installation and one clip 50 is shown in its installed state on the left rail 10. The ends of the constructed panel system can be capped in a variety of ways. For example, where two panel systems meet at a roof's ridge, a ridge vent can be installed. The lower edges of a roof constructed using the present invention can simply have a solid cap attached thereto.

A great advantage of the above-described panel construction system is that the mounting rails and panels can be installed from a flat floor generally found under a roof rafter system. That is, the mounting rails can be attached to (or used as) a roof rafter system while a worker is supported on the flat structure under the roof's rafters. Once the mounting rails are installed, panels are installed on adjacent rails and slid into nested engagement as described above. As with the mounting rails, panels are installed from the flat floor under the roof's rafter system and mounting rails. Note that a repair of such a roof would also take place from the flat floor under the roof's rafters. Thus, the panel construction system of the present invention will reduce or eliminate roofing accidents.

As mentioned above, one or more of the panels used in a panel construction system can incorporate auxiliary features to enhance the utility and/or efficiency of the ultimate structure. A variety of such auxiliary features are presented in the panels illustrated in FIGS. 5A-5E. It is to be understood that the present invention is not limited to these features. In FIG. 5A, a panel 30 incorporates a solar energy conversion structure 60 that can include photovoltaic cells, fluid-carrying tubes, or any other structure/elements used to convert or use solar energy. When structure 60 is used to generate electricity, panel 30 can incorporate electrical wiring with such wiring terminating at connections incorporated in a pin 38 and a recess 40. Such pin and recess electrical connection terminations are well understood in the art. By providing such electrical wiring and terminations, electricity generated at one panel can be readily combined with that generated at other panels and transported within the panel construction system to an end “user” (e.g., devices requiring electric power, power storage devices, etc.).

FIG. 5B illustrates a panel 30 incorporating light transmission structure(s) 62 such as clear, tinted, polarized, or otherwise treated windows. Windows could be a single pane or multiple panes, and could include decorative features such as muntins, stained glass, leaded glass, etc. Such windows could also be translucent. FIG. 5C illustrates a panel 30 incorporating air transmission structure(s) 64 that facilitates the movement of air therethrough. For example, structure 64 could be a vent, a screen, a fan, or combinations thereof. FIG. 5D illustrates a panel 30 incorporating energy transmission structure(s) 66. Structure 66 could be electrical wiring to facilitate transmission of electrical signals and/or power through panel 30. Structure 66 could also be thermal insulation to hinder or block transmission of thermal energy through panel 30. Still further, structure 66 could be ductwork to transport moving air (e.g., from a heating and/or air conditioning system) through panel 30. Finally, FIG. 5E illustrates a panel 30 incorporating condition sensing structure(s) 68 that can be, for example, temperature sensors, intrusion sensors, smoke and/or carbon monoxide sensors, etc. Once again, any electrical signal and/or power wires needed to support structure(s) 68 can be incorporated in panel 30.

The size and weight of a panel used in the present invention can be tailored for a particular installation or could be standardized for most installations. To facilitate the handling of a panel before and during installation/removal thereof, handles can be provided on a panel. For example as illustrated in the FIG. 6 embodiment, two handles 70 are attached to inner region 34 of a panel 30. Such handles could also be formed integrally in region 34. A single handle or more than two handles could also be provided without departing from the scope of the present invention.

The advantages of the present invention are numerous. The panel construction system is a modular approach to both wall and roof construction. Both are installed in the same fashion with roof construction being carried out from a flat floor under a roof's rafter system. This will make roof construction and/or repair considerably safer. The panels are structural and can include a variety of additional features to provide the construction industry with a versatile, safe, and efficient construction system.

Although the invention has been described relative to a specific embodiment thereof, there are numerous variations and modifications that will be readily apparent to those skilled in the art in light of the above teachings. For example, FIGS. 7A and 7B illustrate a panel end construction in accordance with another embodiment of the present invention where common reference numerals are used for those elements that are common to the embodiment illustrated in FIGS. 3A and 3B. At the end of panel 30 that includes pins 38 illustrated in FIG. 7A, the innermost portion of inner region 34 extends slightly in the direction of pins 38 to form a lip 34A and a recessed portion 34B. At the end of panel 30 that includes recesses 40 illustrated in FIG. 7B, the innermost portion of inner region 34 is slightly recessed to form a ledge 34C and an extending portion 34D. The thickness of ledge 34C is equal to the thickness of lip 34A, and the thickness of extending portion 34D is slightly less than that of recessed portion 34B. The depth of recession of ledge 34C is equal to the amount of extension of lip 34A. In this way, when two panels 30 are joined as described above, a tongue-and-groove fit is achieved as the extending portion 34D of inner region 34 associated with one panel 30 fits in the recessed portion 34B of an adjacent panel 30 with lip 34A and ledge 34C abutting one another. The tongue-and-groove fit aids in leak prevention. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described. 

1. A panel construction system, comprising: a plurality of rails, each rail having a longitudinally-extending base with opposing longitudinally-extending L-shaped sides coupled to at least a portion of said base to thereby define a longitudinally-extending T-shaped channel; and a plurality of panels, each panel defining a longitudinally-extending T-shaped channel recessed within an outer surface of said panel at one end thereof and extending from said outer surface at an opposing end of said panel, wherein each side of said panel's channel slidingly engages one of said sides of one of said rails.
 2. A panel construction system as in claim 1 wherein, for each rail, only a first of said L-shaped sides extends continuously along a length of said base.
 3. A panel construction system as in claim 2 wherein, for each rail, a second of said L-shaped sides is discontinuous along said length of said base to thereby define a notched region of said rail, said panel construction system further comprising a longitudinally-extending clip for engagement with said rail along said notched region wherein said clip and said notched region combine to define a substantial L-shape aligned with said second of said L-shaped sides.
 4. A panel construction system as in claim 1, wherein each said panel further comprises: at least one pin extending from said panel at said one end thereof; and at least one recess extending into said panel at said opposing end thereof, wherein each said pin is longitudinally aligned with one said recess, and wherein each said pin and said recess so-longitudinally aligned therewith are commensurate in size.
 5. A panel construction system as in claim 4 wherein, for each said panel, one said pin and one said recess define electrical circuit terminations.
 6. A panel construction system as in claim 1, wherein at least a portion of said panels incorporate at least one auxiliary-function feature.
 7. A panel construction system as in claim 6, wherein said auxiliary-function feature is selected from the group consisting of solar energy conversion features, light transmission features, air transmission features, energy transmission features, and condition sensing features.
 8. A panel construction system as in claim 1, wherein each said rail further comprises at least one mounting element coupled to said base thereof and adapted to be attached to a structure's framing member.
 9. A panel construction system as in claim 1, wherein each said rail further comprises a structural framing element coupled to said base thereof.
 10. A panel construction system as in claim 1, further comprising at least one handle coupled to each said panel.
 11. A panel construction system as in claim 1, wherein said rails are spaced apart and parallel to one another, and wherein each of said panels is slidingly engaged with an adjacent pair of said rails wherein, for each said adjacent pair of said rails, said one end of each of said panels nests with said opposing end of an adjacent one of said panels.
 12. A panel construction system as in claim 11, wherein said one end nesting with said opposing end defines a tongue-and-groove fit.
 13. A panel construction system, comprising: a plurality of rails, each rail having a longitudinally-extending planar base with (i) a first longitudinally-extending L-shaped side coupled to said base along an entire length thereof, (ii) a second longitudinally-extending L-shaped side coupled to said base along a first portion of said entire length thereof and opposing said first side to thereby define a first longitudinally-extending T-shaped channel along said first portion of said entire length of said base, and (iii) a third longitudinally-extending L-shaped side coupled to said base along a second portion of said entire length thereof and opposing said first side to thereby define a second longitudinally-extending T-shaped channel along said second portion of said entire length of said base, wherein a distance is defined between said second side and said third side; and a plurality of panels, each panel defining a longitudinally-extending T-shaped channel (i) recessed within an outer surface of said panel at one end thereof, (ii)extending from said outer surface at an opposing end of said panel, and (iii) having a length that is less than said distance, wherein each side of said panel's channel slidingly engages one of said first side, said second side, and said third side of one of said rails.
 14. A panel construction system as in claim 13, wherein each said panel further comprises: at least one pin extending from said panel at said one end thereof; and at least one recess extending into said panel at said opposing end thereof, wherein each said pin is longitudinally aligned with one said recess, and wherein each said pin and said recess so-longitudinally aligned therewith are commensurate in size.
 15. A panel construction system as in claim 14 wherein, for each said panel, one said pin and one said recess define electrical circuit terminations.
 16. A panel construction system as in claim 13, wherein at least a portion of said panels incorporate at least one auxiliary-function feature.
 17. A panel construction system as in claim 16, wherein said auxiliary-function feature is selected from the group consisting of solar energy conversion features, light transmission features, air transmission features, energy transmission features, and condition sensing features.
 18. A panel construction system as in claim 13, wherein each said rail further comprises at least one mounting element coupled to said base thereof and adapted to be attached to a structure's framing member.
 19. A panel construction system as in claim 13, wherein each said rail further comprises a structural framing element coupled to said base thereof.
 20. A panel construction system as in claim 13, further comprising at least one handle coupled to each said panel.
 21. A panel construction system as in claim 13, wherein said rails are spaced apart and parallel to one another, and wherein each of said panels is slidingly engaged with an adjacent pair of said rails wherein, for each said adjacent pair of said rails, said one end of each of said panels nests with said opposing end of an adjacent one of said panels.
 22. A panel construction system as in claim 21, wherein said one end nesting with said opposing end defines a tongue-and-groove fit.
 23. A panel construction system, comprising: a plurality of rails, each rail having a longitudinally-extending base with a continuous longitudinally-extending L-shaped side coupled to an entire length of said base and a discontinuous longitudinally-extending L-shaped side along said entire length of said base wherein a notched region of said rail is defined in said discontinuous side; a plurality of panels, each panel defining a longitudinally-extending T-shaped channel recessed within an outer surface of said panel at one end thereof and extending from said outer surface at an opposing end of said panel, wherein each side of said panel's channel slidingly engages one of said continuous side and said discontinuous side of one of said rails, each said panel further including at least one pin extending from said panel at said one end thereof and at least one recess extending into said panel at said opposing end thereof, wherein each said pin is longitudinally aligned with one said recess, and wherein each said pin and said recess so-longitudinally aligned therewith are commensurate in size; and a longitudinally-extending clip for engagement with said rail along said notched region wherein said clip and said notched region combine to define a substantial L-shape along said notched region.
 24. A panel construction system as in claim 23 wherein, for Each said panel, one said pin and one said recess define electrical circuit terminations.
 25. A panel construction system as in claim 23, wherein at least a portion of said panels incorporate at least one auxiliary-function feature.
 26. A panel construction system as in claim 25, wherein said auxiliary-function feature is selected from the group Consisting of solar energy conversion features, light transmission features, air transmission features, energy transmission features, and condition sensing features.
 27. A panel construction system as in claim 23, wherein each said rail further comprises at least one mounting element coupled to said base thereof and adapted to be attached to a structure's framing member.
 28. A panel construction system as in claim 23, wherein each said rail further comprises a structural framing element coupled to said base thereof.
 29. A panel construction system as in claim 23, further comprising at least one handle coupled to each said panel.
 30. A panel construction system as in claim 23, wherein said rails are spaced apart and parallel to one another, and wherein each of said panels is slidingly engaged with an adjacent pair of said rails wherein, for each said adjacent pair of said rails, said one end of each of said panels nests with said opposing end of an adjacent one of said panels.
 31. A panel construction system as in claim 30, wherein said one end nesting with said opposing end defines a tongue-and-groove fit. 